Molded foam polystyrene construction kit



May 9, 1967 J. o. KUHN ,3 ,6

MOLDED FOAM POLYSTYRENE. CONSTRUCTION KIT Filed Dec. 23, 1964 3Sheets-Sheet 1 INVENTOR.

May 9, 1967 J. o. KUHN MOLDED FOAM POLYSTYRENE CONSTRUCTION KIT 3Sheets-Sheet 2 Filed Dec. 23, 1964 irra/e/azr May 9, 1967 10. KUHN,318,612

I MOLDED FOAM POLYSTYRENE CONSTRUCTION KIT Filed Dec. 23, 1964 3Sheets-Sheet 3 INVENTOR United States Patent 3,318,612 MOLDED FOAMPOLYSTYRENE CONSTRUCTION KIT James O. Kuhn, Cincinnati, Ohio, assignorto Kennel Products Company, Cincinnati, Ohio, a corporation of DelawareFiled Dec. 23, 1964, Ser. No. 420,609 4 Claims. (Cl. 28079.2)

This invention is directed to a toy construction kit by which a childcan fabricate a number of different types of toys that are sufiicientlylarge to permit the child to get into them or onto them.

The primary objective has been to provide a kit of the type set forth,the major components of which are sufiiciently light in weight to beeasily lifted and handled by a child, even though they are comparativelylarge. Toward this end, the major components of the kit are molded offoamed polystyrene which has been found to be surprisingly strong asused in the kit and so light that even a three-year-old has nodifi'iculty in handling the largest components of the kit.

The key element of the kit is a rectangular base unit having two woodendowel members molded therein that give it remarkable strength. As anexample, it has been found that a grown man may stand at the center ofthe base unit while it is supported at its two ends only withoutbreakage. This base unit is adapted to receive the other components ofthe kit in various ways to make up such different toys as a militarytank, a dolls cradle that rocks, a wheeled coaster, a pull cart, a toylove seat, a table and others, the number being limited only by theimagination of the child using the kit.

Other objectives of the invention will be readily apparent from thefollowing detailed description of the drawings, in which:

FIGURE 1 is a perspective view of a toy military tank made up ofcomponents of the kit of this invention.

FIGURE 2 is a perspective view showing components of the kit made upinto a toy love seat that is adapted to rock.

FIGURE 3 is a perspective view showing parts of the kit made up into atoy cradle that is adapted to rock.

FIGURE 4 shows two of the components of the kit made up to form an easychair.

FIGURE 5 is a perspective view, part of which is broken away, showingthe base unit of the invention.

FIGURE 6 is a perspective view showing a combined rocker and axlejournal.

FIGURE 7 is a perspective view showing a dowel that serves as an axle.

FIGURE 8 is a perspective View showing a preferred form of wheel that ispart of the kit.

FIGURE 9 is a perspective view illustrating the bottom of one of theseat units.

FIGURE 10 is an exploded view in perspective showing the components ofthe kit being assembled to form a wheeled vehicle.

FIGURE 11 is an exploded perspective view showing the parts of the kitwhile being assembled to form the toy military tank of FIGURE 1.

FIGURE 12 is an exploded perspective view showing the components of thekit being assembled to form the easy chair of FIGURE 4.

FIGURE 13 is a side elevational view, shown partly in section, of a toycannon of the type that appears in FIGURE 1.

FIGURE 14 is a fragmentary cross-sectional view taken on a line 14-14 ofFIGURE 13.

In the following detailed description of the drawings,

the dimensions are given by way of illustration only.

3,318,612 Patented May 9, 1967 Specific dimensions are not intended tobe considered critical, although as will be seen, certain dimensionalrelationships are critical, for example, the size of one part withrespect to a second part.

Referring now to FIGURE 5, this figure shows a rectangular base unitdesignated 10. As shown, this base unit, in the preferred embodiment, isroughly two and onehalf times as long as it is wide. The base unit ismolded of foamed polystyrene and it has two wooden dowels 11-11 moldedinto it that extend parallel to the longitudinal center line of theunit, being at the two sides of this center line. As shown, the dowelrods are square in cross section. Preferably, the dowel rods 11 areembedded completely within the base unit, stopping short of the two endsthereof.

Base unit 10 has a total of eight double holes 12 in it that aredisposed in a pattern in which two sets of four each are in each of thetwo endwise portions of the unit. Each double hole 12 consists of twoindividual holes 1313 that are formed such that they taper coming infrom the opposite faces of the unit so that the smallest diameter occursat a point 14 midway between said two faces. The two holes of eachdouble hole have their centers spaced such that the distance between thecenters is approximately equal to three-quarters of the diameter of anindividual hole. On FIGURE 5, this distance between centers isdesignated y. Considering the four double holes that are in the left endof the base unit, as it appears in FIGURE 5, it will be noted thatcorresponding parts, or individual holes of the double holes, are spacedlongitudinally a distance x. This same relationship exists between thecenters of corresponding individual holes of double holes that arealigned transversely going across the base unit. Thus, the four holes inthe left end have corresponding individual holes, the centers of whichare spaced apart a distance x such that their centers are at the fourcorners of a square. This same relationship exists between correspondingindividual holes of the four double holes that are disposed in the rightend as the base unit appears in FIGURE 5. Thus, considering the fourholes that exist in the left part of FIG- URE 5, and considering thecorresponding parts of each one of these holes, there is a hole existingat each corner of two squares that might be said to overlap in the sensethat one is shifted with respect to the other longitudinally of the baseunit by an amount equal to the distance y. The same relationship existsin the pattern of double holes shown at the right in FIGURE 5. Aslightly different relationship exists between those individual parts ofthe double holes that are closest to the center of the base unit, as itappears in FIGURE 5. In this instance, the individual holes of each ofthe four double holes that are farthest from the center of the unit arespaced apart a distance x so that the four sets of double holes near themid portion of the unit are closer together than those two sets of fourthat are in the opposite ends. Otherwise expressed, a member havingplugs thereon that might engage in corresponding individual holes in thepattern of four at the left would engage in opposing holes in thepattern of four that is in the mid portion of the base unit. The aboverelationship of individual holes of the various double holes that areutilized in the base unit is an important one in the fabrication of thevarious toys that can be made using the components of the kit of thisinvention.

Further, FIGURE 5 shows the underside of the base unit, and as shown,there are three recesses in two areas of the base unit extendingtransversely of the unit. Considering those that are in the right handportion of the base unit as it appears in FIGURE 5, there are twotransversely arranged, generally rectangular recesses 15-15 that are inthose areas of the base unit between the respec- Y 3 tive longitudinallydisposed wooden dowels -1111 and the outer side edges of the base unit.There is, in addition, a shorter longitudinally disposed central recess16. In the preferred embodiment, these notches are slightly taperedgoing inwardly and they do not extend more than one-half of the waythrough the. unit going face to face. The same pattern of recesses isrepeated in the other endwise portion of the base unit, these recessesbeing designated 1717 for the ones that are in the areas outside of thetwo wooden dowels 1111 and designated 18 at the middle.

The next majorcomponent of the kit comprises two seat units, designatedgenerally by the numeral 19. Each 7 one of these seat units comprises abottom panel 20, a

back panel 21 and two side panels 2222. Preferably, each seat unit ismolded of foamed polystyrene. It is preferred that the back 21 of eachone of the seat units be straight up and down and that the forward edgesof the two side walls 2222 be straight up and down. However, as shown,the two side walls 2222 may flare outwardly. An important considerationis the plugs 23-23 and the circular, tapered recesses 2424 that are onthe bottom of each one of these seat units. (See FIGURE 9.) Consideringa square traced on the bottom panel 20 of each seat unit, the two plugs2323 are located at diametrically opposed corners of the square,Whereas, the two recesses 24-24 are located at the other two corners ofthis square. The sides of this square are the dimension x, equal to thedimensions x of FIGURE for the base unit 10. Each plug 23-23 is of asize, being tapered, to fit into an individual hole 13 of any one of thedouble holes 12. Furthermore, each one of the two circular recesses24-24 is of a size to receive a tapered plug 23. Thus, as bestillustrated in FIGURES 4 and.

12, two of the individual components 19 may be placed 2323 of one unitengaged in the circular, tapered recesses 2424 of the other, and thus,form an easy chair. Equally important, because of the relationship ofthe various dimensions x, the seat units may be used singly or in twosto form various toys when one or both of the seat units are placed onthe base unit.

As shown in FIGURE 1, two seat units are in place upon the base unit. Ineach instance, the backs 21 of the two units are pointed in the samedirection with the plugs 2323 of the respective units being located inthose individual holes of the set of four at the left that are towardthe left as appears in FIGURE 5 and with the plugs 23-23 of the secondseat unit being placed in those individual holes of the set of fourtoward the right that are toward the right. In this way, the two seatunits are spaced apart as shown in FIGURE 1. The same individual holesof the two sets of four each may be utilized to receive the plugs 2323of two seat units that are placed with the back of one at one side ofthe base unit and the back of the other at the opposite side of the baseunit as appears in FIGURE 3 to form a love seat. As shown in FIGURE 3,two such seat units are mounted in the individual holes of the doubleholes that are closer to the center of the base unit and in this way, adolls cradle may be formed and as will be explained, it is preferredthat rocker components of the kit be used in this toy, It is alsopreferred that the rocker components be used in the love seat as shownin FIGURE 2.

' Referring now to FIGURE 6, a combined rocker and axle journal is shownat 25. This unit has two rectangular lugs 26-26 at the upper sidethereof that are of a size and shape to be received in the two recesses1515, or those designated 1717, that are formed in the bottom side ofthe base unit 10. There is, in addition, a center lug 27 that is adaptedto be received in the recess 16 or the recess 18. It is preferred thattwo such combined rocker and axle journal units 25 be provided with thekit. Unit 25 is preferably formed so that its lower surface is 4 on anare 28, as shown in FIGURE 6, so that when placed on the bottom of thebase unit it forms a rocker as shown in FIGURES 2 and 3. Additionally,the underside of the unit 25 has a slot 29 therein that is designed toreceive a cylindrical wooden dowel 30, the dowel forming an axle. Dowel30, as shown in FIGURE 7, has annular grooves at 3131 at its outer ends,these grooves being designed to receive snap-on washers 3232 that holdwheels 33, such as that shown in FIGURE 8, to the axle. As in the caseof the other major components, the combined rocker and axle journaldevices 25 and the wheels 33 are formed of molded, foamed polystyrene.It is preferred that each one of the wheels- 33 have a relativelysubstantially wide tread 34 and a hub 35 with a central hole 36 of asize to receive either one of the opposite ends of the wooden dowel 30.It is also preferred that the. slot 29 on the underside of the combinedrocker and axle mount be of the size to receivethe wooden dowel in closefriction fit so that no fasteners are necessary in attaching the axle tounit 25. The fit between the bore 36 and the wooden dowel 30 is suchthat the wheel 33 may turn freely on axle 30.

The toy cannon shown in FIGURES l, 13 and 14 is not a part of thisinvention, and thus, it is believed that the illustrations sufiicientlydisclose this part of the toy and that additional descriptive matter isnot necessary.

Having described my invention, I claim:

1. A kit by which a child may fabricate different types of playthingscomprising a rectangular base unit of molded foamed polystyrene, saidbase unit being approximately two and one-half times as long as it iswide, a pair of wooden dowels embedded .in said base unit parallelingthe longitudinal center line thereof on opposite sides of said centerline to strengthen said base unit, there being eight identical doubleholes through said base arranged in two identical sets of four doubleholes each, the individual holes of each double hole being identical andtapering inwardly from the opposite faces of said base unit such thatthe smallest diameter of each hole is. midway be: tween said faces, thecenters of the holes of each double hole being spaced apart a distancein the direction longitudinally of said base unit approximately equal tothree fourths of the diameter of an individual hole at a face of saidbase unit, the centers of corresponding individual holes of the fourdouble holes of each of said sets defining a square at each end of saidbase with the opposite sides of each square paralleling the oppositeside edges of said base unit, those four double holes including two fromeach of the different sets of four that are closer to the center of saidbase unit having the individual holes therein that are farther from saidcenter of said base unit disposed with their centers defining a squareequal in size to the previously mentioned squares, two seat units, eachseat unit of molded foamed polystyrene comprising a bottom, a back andtwo sides, the bottom of each unit having two identical plugs projectingtherefrom and two identical sockets therein of a size to receive a plug,the centers of said sockets and plugs being disposed to define a squareequal in size to the previously mentioned squares with the plugs atdiagonally opposite corners and the sockets be ing diagonally opposed atthe other two corners of said square, and said plugs being of a size tofit individual holes of said double holes in said base unit, wherebysaid seat units may be disposed with their bottoms on said base unitwith their backs at opposite sides thereof, at the same side thereof,facing one another, opposite one another and by utilizing differentindividual holes of said sets of double holes, the seat units may betogether at the center of the base unit or separated at said center.

2. A kit as in claim 1 in which two rockers of molded foamed polystyreneare provided, and means are provided a at the underside of said baseunit to receive said rockers so that they extend transversely of saidbase unit in spaced parallel relation.

3. A kit as in claim 2 in which two sets of two molded foamedpolystyrene wheels and axles therefor are provided, and said rockersadapted to receive said axles.

4. A kit by which a child may fabricate different types of playthingscomprising a rectangular base unit of molded foamed polystyrene, therebeing eight identical double holes through said base arranged in twoidentical sets of four double holes each, the individual holes of eachdouble hole being identical and tapering inwardly from the oppositefaces of said base unit such that the smallest diameter of each hole ismidway between said faces, the center lines of the holes of each doublehole being spaced apart a distance in the direction longitudinally ofsaid base unit approximately equal to three fourths of the diameter ofan individual hole at a face of said base unit, the centers ofcorresponding individual holes of the four double holes of each of saidsets defining a square at each end of said base with the opposite sidesof each square paralleling the opposite side edges of said base unit,those four double holes including two from each of the different sets offour that are the ones closer to the center of said base unit having theindividual holes therein that are farther from said center of said baseunit disposed with their centers defining a square equal in size to thepreviously mentioned squares, two seat units, each seat unit comprisinga bottom, a back and two sides, the bottom of each unit having twoidentical plugs projecting therefrom and two identical sockets thereinof a size to receive a plug, the centers of said sockets and plugs beingdisposed on a square equal in size to the previously mentioned squarewith the plugs at diagonally opposite corners and the sockets beingdiagonally opposed at the other two corners of said square, and saidplugs being of a size to fit individual holes of said double holes.

References Cited by the Examiner UNITED STATES PATENTS 3,261,619 7/1966Norgaard et al 28079 RICHARD C. PINKHAM, Primary Examiner.

R. F. CUTTING, Assistant Examiner.

1. A KIT BY WHICH A CHILD MAY FABRICATE DIFFERENT TYPES OF PLAYTHINGSCOMPRISING A RECTANGULAR BASE UNIT OF MOLDED FOAMED POLYSTYRENE, SAIDBASE UNIT BEING APPROXIMATELY TWO AND ONE-HALF TIMES AS LONG AS IT ISWIDE, A PAIR OF WOODEN DOWELS EMBEDDED IN SAID BASE UNIT PARALLELING THELONGITUDINAL CENTER LINETHEREOF ON OPPOSITE SIDES OF SAID CENTER LINE TOSTRENGTHEN SAID BASE UNIT, THERE BEING EIGHT IDENTICAL DOUBLE HOLESTHROUGH SAID BASE ARRANGED IN HOLES OF EACH DOUBLE HOLE BEING IDENTICALAND TAPERING INWARDLY FROM THE OPPOSITE FACES OF SAID BASE UNIT SUCHTHAT THE SMALLEST DIAMETER OF EACH HOLE IS MIDWAY BETWEEN SAID FACES,THE CENTERS OF THE HOLES OF EACH DOUBLE HOLE BEING SPACED APART ADISTANCE IN THE DIRECTION LONGITUDINALLY OF SAID BASE UNIT APPROXIMATELYEQUAL TO THREE FOURTHS OF THE DIAMETER OF AN INDIVIDUAL HOLE AT A FACEOF SAID BASE UNIT, THE CENTERS OF CORRESPONDING INDIVIDUAL HOLES OF THEFOUR DOUBLE HOLES OF EACH OF SAID SETS DEFINING A SQUARE AT EACH END OFSAID BASE WITH THE OPPOSITE SIDE OF EACH SQUARE PARALLELING THE OPPOSITESIDE EDGES OF SAID BASE UNIT, THOSE FOUR DOUBLE HOLES INCLUDING TWO FROMEACH OF THE DIFFERENT SETS OF FOUR THAT ARE CLOSER TO THE CENTER OF SAIDBASE UNIT HAVING THE INDIVIDUAL HOLES THEREIN THAT ARE FARTHER FROM SAIDCENTER OF SAID BASE UNIT DISPOSED WITH THEIR CENTERS DEFINING A SQUAREEQUAL IN SIZE TO THE PREVIOUSLY MENTIONED SQUARES, TWO SEAT UNITS, EACHSEAT UNIT OF MOLDED FOAMED POLYSTYRENE COMPRISING A BOTTOM, A BACK ANDTWO SIDES, THE BOTTOM OF EACH UNIT HAVING TWO IDENTICAL PLUGS PROJECTINGTHEREFROM AND TWO IDENTICAL SOCKETS THERIN OF A SIZE TO RECEIVEA PLUG,THE CENTERS OF SAID SOCKETS AND PLUS BEING DISPOSED TO DEFINE A SQUAREEQUAL IN SIZE TO THE PREVOUSLY MENTIONES SQUARES WITH THE PLUGS ATDIAGONALLY OPPOSITE CORNERS AND THE SOCKETS BEING DIAGONALLY OPPOSED ATTHE OTHER TWO CORNERS OF SAID SQUARE, AND SAID PLUGS BEING OF A SIZE TOFIT INDIVIDUAL HOLES OF SAID DOUBLE HOLES IN SAID BASE UNIT, WHEREBYSAID SEAT UNITS MAY BE DISPOSED WITH THEIR BOTTOMS ON SAID BASE UNITWITH THEIR BACKS AT OPPOSITE SIDE THEREOF, AT THE SAME SIDE THEREOF,FACING ONE ANOTHER, OPPOSITE ONE ANOTHER AND BY UTILIZING DIFFERENTINDIVIDUAL HOLES OF SAID SETS OF DOUBLE HOLES, THE SEAT UNITS MAY BETOGETHER AT THE CENTER OF THE BASE UNIT OR SEPARATED AT SAID CENTER.